Modeling and Analysis of Rotor Shaft Assembly of Hammer Mill Crusher

Modeling and Analysis of Rotor Shaft Assembly of Hammer Mill Crusher
CHAPTER 1
INTRODUCTION
A crusher is a machine designed to reduce large solid material objects into a smaller
volume, or smaller pieces. Crushers may be used to reduce the size, change the form,
of waste materials so they can be more easily disposed or recycled, and to reduce the
size of a solid mix of raw materials (as in rock ore), so that pieces of different
composition can be differentiated. Crushing is the process of transferring a force
amplified by mechanical advantage through a material made of molecules that bond
together more strongly, and resist deformation more, than those in the material being
crushed. Crushing devices hold material between two parallel or tangent solid
surfaces, and apply sufficient force to bring the surfaces together to generate enough
energy within the material being crushed so that its molecules separate from
(fracturing), or change alignment in relation to (deformation), each other. The earliest
crushers were hand-held stones, where the weight of the stone provided a boost to
muscle power, used against a stone anvil. Querns and mortars are types of these
crushing devices.
1.1 Description
In industry, a crusher is typically a machine which uses a metal surface to break or
compress materials. Mining operations use crushers, commonly classified by the
degree to which they fragment the starting material, with primary and secondary
crushers handling coarse materials, and tertiary and quaternary crushers reducing ore
particles to finer gradations. Typically, crushing stages are followed by milling stages
if the materials need to be further reduced. Crushers are used to reduce particle size
enough so that the material can be processed into finer particles in a grinder. A typical
circuit at a mine might consist of a crusher followed by a SAG mill followed by a ball
mill. In this context, the SAG mill and ball mill are considered grinders rather than
crushers.
Dept. of Mechanical Engineering 1

1.2 Types of Crushers
 Jaw Crusher
 Impact Crusher
 Hammer Crusher
 Cone Crusher
 Roll Crusher
 Wood Crusher
1) Jaw crusher
Jaw Crusher is mainly used to crush kinds of mining stones primarily, and the largest
compression resistance of the material is 320MPa. The jaw crusher is widely used in
stone mining, metallurgy industry, building material, highway, railway, and chemical
industry.
Working Principle:
The motor transmits power through belt, drives the moving jaw to do periodic motion
towards the fixed jaw by the eccentric shaft. The angle between toggle plate and
moving jaw plate increases when moving jaw moves. So the moving jaw moves
towards the fixed jaw. The stuff will be crushed in this process. The angle between
toggle plate and moving jaw decreases when moving jaw moves down, the moving
jaw moves leaves fixed jaw by pulling rod and spring, the final crushed stuff will be
discharged from the outlet.
Features:
1. simple structure, easy maintenance.
2. stable performance.
3. even final particles and high crushing ratio.

Fig 1.1 Jaw crusher
2) Impact crusher
Impact crusher is widely applied in mining, transportation, energy, construction and

chemical industry. They are ideal choice for crushing and screening. This machine
features reasonable structure, high productivity, easy operation and maintenance and
safe performance. The most outstanding advantage of this machine is that its finished
powder is in good, cubic shape and without tensility and cranny.
Features and Benefits:

1. High reduction ratio and crushing efficiency.
2. No-board connection; The blow bar with high chrome(high chromed blow bar).
3. Impact plate with a special shape.
4. Crushed product with cubical shape.
5. Easy maintenance and reliable operation.

Working Principle:
This impact crushes materials with impact force. When the materials enter the blow
bar area, they are crushed due to the high-speed impact of the blow bar and are
thrown to the impact plates on the rotor for secondary crush. Then the materials will
be shot back to the blow bar again for the third crush. This process repeats until the
materials are crushed to the required size and discharged from the lower part of the
machine.
The size and shape of the finished powder can be changed by adjusting the gap
between the impact rack and rotor support
Fig 1.2 Impact crusher

3) Cone crusher
Designed on layered crushing theory, and with features of reliable structure,

convenient adjustment and economical operation, the Cone Crusher is applicable to
break various ores and rocks with medium or above height.
Fig 1.3 Cone Crusher
4) Roll crusher
Heavy-Duty Drive Shafts & Bearings Oversized, heat-treated, alloy steel shafts plus
self-aligning, roller-type bearings assure long life and maximum use of power.
Jackshafts for control of roller speed are standard on double roll crushers, optional on
larger single roll crushers.
Fig 1.4 Roll crusher

5) Wood crusher
Wood Crusher is suitable for crushing raw wood with size less than 200mm
(diameter). After milled, the output size can be as small as diameter 3-5 mm , which is
suitable for further palletizing or briquette.
Fig 1.5 Wood crusher
1.3 The types of crushing

There are four basic ways to reduce a material by impact, attrition, shear or
compression — and most crushers employ a combination of all these crushing
methods.
1) Impact
2) Attrition
3) Shear
4) Compression
1) Impact
In crushing terminology, impact refers to the sharp, instantaneous collision of one
moving object against another. Both objects may be moving, such as a baseball bat
connecting with a fast ball, or one object may be motionless, such as a rock being
struck by hammer blows.

There are two variations of impact: gravity impact and dynamic impact. Coal
dropped onto a hard surface such as a steel plate is an example of gravity impact.
Gravity impact is most often used when it is necessary to separate two materials
which have relatively different friability. The more friable material is broken, while
the less friable material remains unbroken. Separation can then be done by screening.
Fig 1.6 Impact crushing
2) Attrition
The Attrition is a term applied to the reduction of materials by scrubbing it between
two hard surfaces. Hammer mills operate with close clearances between the hammers
and the screen bars and they reduce by attrition combined with shear and impact
reduction. Though attrition consumes more power and exacts heavier wear on
hammers and screen bars, it is practical for crushing the less abrasive materials such
as pure limestone and coal.
Attrition crushing is most useful in the following circumstances:
— when material is friable or not too abrasive
— when a closed-circuit system is not desirable to control top size
Fig 1.7 attrition crushing

3) Shear
Shear consists of a trimming or cleaving action rather than the rubbing action
associated with attrition. Shear is usually combined with other methods. For example,
single-roll crushers employ shear together with impact and compression.
Shear crushing is normally called for under these conditions:

— when material is somewhat friable and has a relatively low silica content
— for primary crushing with a reduction ratio of 6 to 1
— when a relatively coarse product is desired, usually larger than 1 h/2 (38mm) top
size
Fig 1.8 Shear crushing
4) Compression
As the name implies, crushing by compression is done between two surfaces, with the
work being done by one or both surfaces. Jaw crushers using this method of
compression are suitable for reducing extremely hard and abrasive rock. However,
some jaw crushers employ attrition as well as compression and are not as suitable for
abrasive rock since the rubbing action accentuates the wear on crushing surfaces.
As a mechanical reduction method, compression should be used as follows:

—if the material is hard and tough
—if the material is abrasive

—if the material is not sticky

—where the finished product is to be relatively coarse, i.e., 1 h/2 (38mm) or larger
top size
—when the material will break cubically
Fig 1.9 Compression crushing
1.4 Scope of Project
Computer aided design is essential to design the given crusher such that the
component can be viewed before manufacturing any modifications can be made in
the design if required and also we can have different sizes of crusher at a single time
without going to the manual process. The load withstanding capacity of different
component can be found out. Finally by checking the design and with standing
capacity of the component is then manufactured manual.

CHAPTER 2
LITERATURE REVIEW
1. [R B Choudary has published a book “Introduction to Ansys 16.0”,
Publications I K International Publishing House Pvt. Ltd, Edition 2, pages-
332]
About ansys software and features of it are known from this book. For a
beginner it provides detailed information about the software.
2. [R. Bruce hopkins has published a book “Design analysis of shafts and
beams”, Publications mc graw hill, pages-475]
Design procedure of shaft is observed from this book. And obtained
dimensions of shaft are taken.
3. [RS Khurmi has published a book “Strength of Materials”, Publications

SChand, pages-880]
About different types of stresses and behaviour of materials when these
stresses act on it individually or combined.
4. [Sham Tickoo has published a book “Ansys workbench 14.0 For Engineers
and Designers”, Publications Dreamtech press, Year 2013, Pages-412]
Types of analysis and their Detailed procedure is taken from this book.
5. [S. Md. Jalaludeen has published a book “Design data handbook”]

In shaft calculations, factor of safety for different conditions such as varying
or shock loads are required. These are obtained from this data book.

CHAPTER 3
HAMMER MILL CRUSHER
3.1 Construction of machine

The hammer mill crusher consists of a robust fabricated MS body of hinged type for
ease of maintenance. Accordingly, the top cover is also divided into three parts, two
removable and one fixed part. The crusher gets its motion from a electric motor
through v-belt drive.
Hammer mill crusher mainly consists of the following parts:
Body
Body of a Hammer mill crusher consists of a base frame it is fabricated from thick
MS plates and ribs are provided along the line of stresses, so, as to give maximum
strength and minimum vibrations.
Bearings
The whole rotor is supported by two no self-aligned roller bearings, housed in
Plummer blocks, which are located outside the body.
Rotor shaft
Shaft is made of special steel and is supported at both ends by means of two roller
bearings. The central part of crusher is called rotor. The rotor consists of a heavy shaft
machined and assembled with MS discs and spacers in between discs.

Hammers
The MS discs has holes spaced at 120º for intersection of pins on which hammers are
mounted. These hammers are free to rotate about their own axis and are made up of
manganese steel for high resistance towards wear.
Breaker plate
The breaker plate is held by EN 8 shafts on both top and bottom sides around rotor.
The coal is crushed to the required size between the breaker plate and the rotated
hammers.
Liner plates
The liner plates are made out of manganese steel, which is a very hard material and
has high resistance towards wear. The breaker plate, on which the liner plates are
mounted, can be adjusted through take-up screws and nuts to adjust the size of the
crushed coal.
Driving motor
The foundation frame of the Driving Motor is provided by projection on one side of
the Hammer mill crusher and supports from base frame are also provided to hold the
motor foundation. The size of motor varies as per the size of Crusher. Normally
squirrel cage motor of 980 RPM is provided
Driving pulley
This pulley is provided on one side of the center shaft with two v- grooves on it. It is
directly coupled with driving motor with the help of 2 Nos. of v- belts. The dia of
driving pulley has been calculated as per the requirement of No. of vibration per
second

3.2 Operating Principle

In Hammer mill machine, the motor drives the rotor to rotate at high speed through
the belt and on the rotor there are series of hammers. When the materials get into that
working area of the hammers the rotating hammers with the high rotation speed are
crushing them the crushed products meeting the require shape can be discharged by
the outlet and become the final products
3.3 Working of machine

When coal is delivered to the hammer mill crusher, it is prepared for cyclone furnace
firing by being crushed into 1/4 inch or smaller size coal. Coal enters from the top and
is violently thrown against the breaker blocks by the hammers. The final crushing is
done between the hammer faces and the screen bars. Then the crushed coal goes to the
conveyors below and is carried to the storage bunker. Tramp iron or material that will
not go out between the screen bars is dropped into the iron pocket and is later
removed.

INLET TO
VOLUTE CRUSHER
CASING
LINERS
HAMMERS
SHAFT
ROTOR
SPRING
LOADED
ADJUSTER
Fig 3.1Hammer Mill crusher
The final crushing is done between the hammer faces and the screen bars. Then the
crushed coal goes to the conveyors below and is carried to the storage bunker. Tramp
iron or material that will not go out between the screen bars is dropped into the iron
pocket and is later removed.

3.4 Hammer mill features:

 Material is reduced by impact from free-swinging bar hammers
 Finished Product size controlled by grates or crusher sizes
 Materials can be reduced to granular powder at high rate.
 Heavy-duty cast-iron or carbon steel construction
 Right-hand or left-hand machine available
 Easy access for maintenance and crusher/grate change
3.5 Applications of Hammer mill crushers:

 Recycling glass
 Feed industry
 Stone crushing
 Size reduction of waste materials
 Electronics recycling
 Ceramics
 Pulverization of sea shells
 Minerals
 Wood particles for fuel wood
 Limestone

CHAPTER 4
DESIGN OF SHAFT
Introduction
A shaft is a rotating machine element which is used to transmit power from one place
to another. The power is delivered to the shaft by some tangential force and the
resultant torque (or twisting moment) set up within the shaft permits the power to be
transferred to various machine linked up to the shaft.
The following stresses are induced in the shafts:

1. Shear stresses due to the transmission of torque (i.e. due to torsional load).
2. Bending stresses (tensile or compressive) due to the forces acting upon
machine element like gears, pulleys etc.
3. Stresses due to combined torsional and bending loads
4.1 Classification of shafts
Shafts involved in power transmission may be classified as

1) Transmission shafts are used to transmit power between source and the machines
using the power. They include line shafts, jack shafts and counter shafts.
i) Line shaft is a long continuous shaft which receives power from the
source and distribute to different machines.
ii) Jack shaft is directly connected to the source of power and from which
other shafts are driven.
iii) Counter shafts receive power from line shaft and transmit to a machine.
2) Machine shafts are incorporated within the machine, such as crank shaft.

4.2 Material used for shafts

The material used for shafts should have the following properties:
1. It should have high strength
2. It should have good machinability
3. It should have low notch sensitivity.
4. It should have good heat treatment property.
5. It should have high wear resistant property.
Depending on the requirement, the shafts can be made of plain carbon steel or alloy
steel.
4.3 Design of shafts

The shafts may be designed on the basis of
1) Strength and 2) rigidity and stiffness
In designing shafts on the basis of strength, the following cases may be considered:
1) Shafts subjected to twisting moment or torque only.
2) Shafts subjected to bending moment only.
3) Shafts subjected to combined twisting and bending moment
Shafts subjected to axial loads in addition to combined torsion & bending loads

CHAPTER 5
SHAFT CALCULATIONS
Shafts subjected to twisting moment or torque only:
When the shaft is subjected to twisting moment (or torque) only, then the diameter of
the shaft may be obtained by using the torsion equation. We know that
Where,
T=Twisting moment acting on the shaft, Nmm
J=Polar moment of inertia of the shaft about the axis of rotation, m
Fs =Torsional shear stress, N/ m

r=Distance from neutral axis to the outer most fiber
=d/2 mm
G= modulus of rigidity N/ m
= angle of twist or torsional deflection, radians and
L= length of shaft, mm
We know for solid shaft, polar moment of inertia,
The equation may be written as

Or
Twisting moment (T) may be obtain by the following relation:
In S.I units, power transmitted (in watts) by the shaft,
P=2ΠNT/60 or T=P*60/2ΠN
Where,
T=Twisting moment in N-m
N=Speed of the shaft in RPM
In M.K.S units, horse power transmitted by the shaft,
P=2ΠNT/4500 or T=P*4500/2ΠN
Where,
T=Twisting moment in Kgf-m and
N=Speed of the shaft in RPM
Shafts subjected to bending moment only:

When the shaft is subjected to a bending moment only, then the maximum stress
(tensile or compressive) is given by the bending equation. We know that

Where,
M=Bending moment, N-mm
I=Moment of inertia of cross-sectional area of the shaft about the
axis of rotation,
Fb =Bending stress, N/ and

Y=Distance from neutral axis to the outer-most fiber, mm
E= Modules of elasticity N/
R = Radius at which load as stated act, mm
We know that for a round solid shaft, moment of inertia,
and y=d/2
Substituting these values in the equation:
Shafts subjected to fluctuating loads:
In above equations shafts are subjected to constant twisting moment & bending
moment but in actual practice shafts are subjected to fluctuating torque & bending
moments. In order to design such shafts like line shaft &counter shaft combined shock
& fatigue factor to be considered for calculating twisting moment and bending
moment
Substituting these factors in above equations

For maximum shear stress theory
For maximum normal (tensile or compressive) theory
Where:
M= Bending Moment
fb = Bending stress
T = Twisting moment (Torque) upon the shaft
fs = Tensional shear stress
Km = Combined shock & fatigue factor for bending
Kt -= Combined shock & fatigue factor for twisting
d = diameter of the shaft

RECOMMENDED VALUES FOR Km & Kt
Nature of Load Km Kt
Stationary shafts
Gradually Applied Loads 1.0 1.0
Suddenly Applied Loads 1.5 to 2.0 1.5 to 2.0
Rotating shafts
Gradually Applied Loads 1.5 1.5
Suddenly Applied Loads 1.5 to 2.0 1.5 to 2.0

with minor shock
2.0 to 3.0 2.0 to 3.0
Suddenly Applied Loads
with major shock
Shaft calculations:
Data obtained from industry:

• Speed = 740rpm
• Distance between bearing = 1200mm
• Bearing diameter = 80mm
• Power = 50 Hp (37.28 Kw)
=37.3*10^3 W
• Mass =746.25kg
=7320.71 N
• From data book
• Ultimate shear stress = 650 kg/
= 63.765 N/
• Bending stress = 600 kg/
= 58.86 N/

Power
P=[
P = (2 / 60
(60*P)/ 2 N=T
Torque,
T = (60*37.3*10^3) / (2* * 740)

= 481.33 Nm
= 481330 Nmm
Bending moment
M = (W*L) / 8
= (7320.71*1200) / 8
= 1098106.55 Nmm
Considering combined bending and twisting moment:
d = 58.28mm

Fluctuating load:
= 165878.01
d = 55mm
Consider diameter of shaft = 60 mm
Shear stress, fs =
T=
Fs =
fs = = 11.34 N/
Factor of safety:
= 5.62
Condition factor of safety
steady loads 3-4
Varying or reversal loads 6-8
Shock loads 9-16
• We have selected diameter = 62mm

fs=
fs=
fs= 10.28
factor of safety :
= = 6.20
We consider only for varying loads
Deflection,
Moment of inertia, I =
= 725331.69N/
Deflection
= 0.011mm
Selected diameter of shaft = 62mm

CHAPTER 6
DESIGN OF BEARING
6.1. Introduction:
A bearing is a machine element which supports another moving machine element
knows as journal. It permits a relative motion between the contact surfaces of the
member, while carrying the load. The efficiency of the mechanical system depends to
a great extent on the efficiency of its bearings.
A necessity for the efficient working of the bearings is that the running surface
should be adequately supplied with lubricant. For this purpose the oil is supplied
through a lubricating ring firmly clamped on the shaft at the after end and a wiper
device fitted in the upper part. This device, together with correctly formed oil grooves
in the bearing shells ensure that in bearings the oil supply is maintained in all
circumstances even at low revolutions.
6.2. Classification of bearings:
Bearings may be classified as given below
1. Depending upon the direction of load to be supported. The bearing under this
group are classified as
a) Radial bearings: The load acts perpendicular to the direction of motion of the
moving element.
b) Thrust bearings: The load acts along the axis of rotation.
2. Depending upon the nature of contact. The bearing under this group are
classified as:

a) Sliding contact bearings: The sliding takes place along the surface of contact
between the moving element and the fixed element. The sliding contact
bearing are also knows as plain bearings. To minimize the friction these
surfaces are usually separated by film of lubrication.
b) Rolling contact bearings: The steel balls or rollers are interposed between the
moving and fixed element. The object of rolling contact bearing is to minims
the friction by substituting pure rolling motion for sliding motion. Since the
rolling friction is much less than the sliding friction, rolling contact bearings
are called anti-friction bearings.
6.3 Bearings used in crusher:

Mainly rolling contact bearings are applicable in crushers because they have the
following advantages.
• Can be adopted for combined radial and axial loads without any
complications.
• More compact design
• Maintenance cost is low
• Low starting friction
• Easier to provide lubrication and requires small consumption of lubrication
• Accuracy alignment of parts can be maintained
• Reliable in service
• The dimensions are internationally standardized
The following bearings are used in crushers:
1) Deep groove ball bearings

2) Cylindrical roller bearings
3) Spherical roller bearings
4) Tapered roller bearings

1) Deep groove ball bearings:
A) Single Row Deep Groove Ball Bearings:

This bearing consists of inner and outer rings with deep symmetrical ball race,
ways, separator and complement of Balls. This beading is designed primarily
for radial load but due to its design features it is capable of carrying equal
amount of thrust load in either direction and is capable of operating at high
speed too.
This bearing has the lowest frictional losses and therefore, it is the most widely
used among all types of bearings.
Fig 6.1 Single row deep groove ball bearing
B) Double Row Deep Groove Ball Bearings:
Double row deep groove bearing embodied the same design principle as that of the
single row deep groove ball bearings.

The bearing has a lower axial displacement than it occurs in the single row deep
groove ball bearing. These bearings are capable of carrying substantial thrust loads in
either direction and due to double rows of ball they are also capable of carrying.
2) Cylindrical Roller Bearings:

In this type of bearings, the rollers race tracks are essentially cylindrical, however
they may be ground slightly curved in order to achieve thereby small degree of
flexibility.
Fig 6.2 Cylindrical roller bearing
The rollers are guided between two lips on either the inner race or the outer race.
Other types provided with no lip, one lip or two lips, according to the function which
the bearing has to perform. Ball Bearings have a point contact on the races whereas all
types of cylindrical roller bearings have a line contact.
Due to line contact the cylindrical roller bearings have a very high radial load
carrying capacity as compared to ball bearings of the same size. Due to their separable
design, cylindrical roller bearings are more convenient for mountings than ball
bearings
3) Spherical roller bearing:
A spherical bearing is a bearing that permits angular rotation about a central point in
two orthogonal directions within a specified angular limit based on the bearing

geometry. Typically these bearings support a rotating shaft in the [bore] of the inner
ring that must move not only rotationally, but also at an angle.
Construction of spherical bearings can be hydrostatic or strictly mechanical. A
spherical bearing by itself can consist of an outer ring and an inner ring and a locking
feature that makes the inner ring captive within the outer ring in the axial direction
only. The outer surface of the inner ring and the inner surface of the outer ring are
collectively considered the raceway and they slide against each other, either with a
lubricant or a maintenance-free based liner. Some spherical bearings incorporate a
rolling element such as a race of ball-bearings, allowing lower friction. The design of
this bearing permits radial load and heavy thrust load in either direction.
Fig 6.3 Spherical roller bearing
4) Tapered roller bearing:
Taper roller bearing consists of two main units, a cup and a cone. The cup is on the
outer race whereas the cone consists of inner race, the separator and compliment of
taper rollers. The taper rollers are guided by the high load on the inner race. The taper
roller bearings are manufactured with interchangeable cups and cone on the shaft
separately.

Fig 6.4 Tapered roller bearing
These bearings are capable of carrying both the radial and axial loads and permit fine
adjustment for end play. Greater care is required to ensure the proper alignment of
bearings and maintenance of proper axial clearance is essential to avoid bearing
failure. Due to more development in the design of the taper roller bearings, these are
also available with 2 rows and 4 rows.

CHAPTER 7
MODELING COMPONENTS
Fig 7.1 Bearing Assembly
Fig 7.2 Hammer

Fig 7.3 Hammer Pin
Fig 7.4 Gland Seal
Fig 7.5 Main Shaft

Fig 7.6 End Disc Plates
Fig 7.7 Spacer
Fig 7.8 Disc Plates

Fig 7.9 Rotor shaft assembly of hammer mill crusher

CHAPTER 8
FINITE ELEMENT METHOD
8.1 INTRODUCTION:
The limitations of the mind are such that it cannot grasp the behavior of its complex
surrounding and creation in one operation. Thus the purpose of sub dividing all
systems into their individual components or elements whose behavior is readily
understood and the re building the original system from such components to study its
behavior is natural way in which a engineer, the scientist or even the economist
proceeds. Finite element method, which is a powerful tool for analyzing various
engineering problems, owes is origin to the above mentioned way in which a human
mind works J.N.Reddy.
The basic idea in the FEM is to find the solution of complicated problems by
replacing it by a simpler one. Since the actual problem is replaced by a simpler one in
finding solution , be will be able to find only an approximate solution rather than the
exact solution. The existing mathematical tools will not be sufficient to find the exact
solutions (and some times, even an approximate solutions) of most of the practical
problems. Thus in the absence of any other covenant method to find even the
approximate solution of given problem, we have to prefer the FEM. the FEM
basically consists of thus following procedure. First, a given physical or mathematical
problems is modeled by dividing it into small inter connecting fundamental parts
called “Finite element”. Next, an analysis of the physical or mathematics of the
problem is made on these elements: Finally, the elements are re-assembled into the
whole with the solution to the original problem obtain through this assembly
procedure.
The finite element method has developed simultaneously with the increasing use of
high speed electronic digital computers and with the growing emphasis on numerical
method for engineering analysis. Although the method was original developed for

structural analysis the general nature of the theory on which it is based has also made
possible us successful application for so of problem in other fields of engineering.
GENERAL DESCRIPTION OF THE FINITE ELEMENT

METHOD:
In the finite element method, the actual continuum or body of matter like solid,
liquid or gas is represented as assemblage of sub divisions called finite elements.
These elements are considered to be interconnected at specified , which are called
nodes or nodal points. The nodes usually lie on the element boundaries where
adjacent elements are considered to be connected. Since the actual variation of the
field variable (like displacement, stress, temperature, pressure and velocity) inside the
continuum is not known, we assume that the variation of field variable inside a finite
element can be approximated by a simple function. These approximating functions
(also called interpolation models) are defined in terms of the values at the nodes.
When field equations (like equilibrium equations) for the whole continuum are
written, the new will be the nodal values of the field variable. By solving the field
equation, which is generally in the form of matrix equations, the nodal values of the
field variable will be known. Once these are known, the approximating function
defines the field variable throughout the assemblage of elements.
8.2 STRUCTURAL ANALYSIS:

Structural analysis is probably the most common application of the finite element
method. The term structural (or structure) implies not only civil engineering structures
such as ship hulls, aircraft bodies, and machine housings, as well as mechanical
components such as pistons, machine parts, and tools.

8.3 Types Of Structural Analysis:

Different types of structural analysis are:
• Static analysis
• Modal analysis
• Harmonic analysis
• Transient dynamic analysis
• Spectrum analysis
• Bucking analysis
• Explicit dynamic analysis
Static analysis:
A static analysis calculates the effects of steady loading conditions on a structure,
while ignoring inertia and damping effects, such as those caused by time varying
loads. A static analysis can, however, include steady inertia loads (such as gravity and
rotational velocity), and time-varying loads that can be approximated as static
equivalent loads (such as the static equivalent wind arid seismic loads commonly
defined in many building codes).
Static analysis is used to determine the displacements, stresses, strains, and forces
in structural components caused by loads that do not induce significant inertia and
damping effects. Steady loading and response are assumed to vary slowly with respect
to time.
The kinds of loading that can be applied in a static analysis include:

 Externally applied forces and pressures
 Steady-state inertial forces (such as gravity or rotational velocity)
 Imposed (non-zero) displacements
 Temperatures (for thermal stain)
 Fluences (for nuclear swelling)

A static analysis can be either linear or non-linear. All types of non-linearities are
allowed-large deformations, plasticity, creep, stress, stiffening, contact (gap)
elements, hyper elastic elements, and so on.
Over-view of steps in a static analysis:

The procedure for a modal analysis consists of three main steps:
1. Build the model.
2. Apply loads and obtain the solution.
3. Review the results.
BASIC STEPS IN ANSYS (Finite Element software):
PREPROCESSOR
Building model and modeling
SOLUTION
Loading and solving
POST PREPROCESSOR
Reviewing results
Preprocessing (defining the problem): The major steps in

preprocessing are given below
 Define key points/lines/ areas/volumes.
 Define element type and material/geometric properties
 Mesh lines/ areas/volumes as required.
The amount of detail required will depend on the dimensionality of the analysis
(i.e., 1D, 2D, axi-symmetric, 3D).

Solution (assigning loads, constraints, and solving):

Here the loads (point or pressure), constraints (translational and rotational) are
specified and finally solve the resulting set of equations.
Post processing: In this stage, further processing and viewing of the results can be
done such as:
 Lists of nodal displacements
 Element forces and moments
 Deflection plots
 Stress contour diagrams

CHAPTER 9
ANALYSIS
Fig 9.1 3-D MODEL OF SHAFT IN ANSYS

Fig 9.2 VON-MISES STRESS OBTAINED IN ANSYS

Fig 9.3 DEFORMED OF SHAFT

CHAPTER 10
RESULT
By Applying different types of loads like torsion and bending loads on shafts
deformation and stress values are obtained. Same is done by analysis and
values are obtained. They are listed below
• Theoretical deformation value= 0.011 mm.
• Stress obtained = 10.28 N/
• Ansys deformation value = 0.0841 mm
• Ansys stress = 16.63 N/

CHAPTER 11
CONCLUSION
By comparing theoretical and analytical values we conclude that,
Theoretical values are less then the analytical values i.e., shaft is subjected to stress
which is less than the shaft fracture point.
Therefore practical values are less than maximum values so we can conclude the shaft
diameter as 62mm which is in safe limits.

CHAPTER 12
BIBLIOGRAPHY
• Strength of materials by “RS KHURMI” from s.chand publications.

Design data book by “V B BHANDARI” from mc graw hill publications.
• Design analysis of shafts and beams by “R.BRUCE HOPKINS” from mc graw
hill.
• Design data handbook by “ S.MD.JALALUDEEN” .
• Design data book by “K.MAHADEVAN” from CBS publishers.
• Design of machine elements by “ V B BHANDARI” mc graw hill
publications.
• C.M.T.I hand book
• www.skfbearings.com
• www.roysmech.co.in
• www.mechanicalproperties.com
• www.hammermill.com

Modeling and Analysis of Rotor Shaft Assembly of Hammer Mill Crusher

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Modeling and Analysis of Rotor Shaft Assembly of Hammer Mill Crusher

Dept. of Mechanical Engineering 1

1.2 Types of Crushers

3. even final particles and high crushing ratio.

Dept. of Mechanical Engineering 2

Fig 1.1 Jaw crusher

Impact crusher is widely applied in mining, transportation, energy, construction and

Features and Benefits:

Dept. of Mechanical Engineering 3

Fig 1.2 Impact crusher

Dept. of Mechanical Engineering 4

Designed on layered crushing theory, and with features of reliable structure,

Fig 1.3 Cone Crusher

Fig 1.4 Roll crusher

Dept. of Mechanical Engineering 5

Fig 1.5 Wood crusher

1.3 The types of crushing

Dept. of Mechanical Engineering 6

Fig 1.6 Impact crushing

Fig 1.7 attrition crushing

Dept. of Mechanical Engineering 7

Shear crushing is normally called for under these conditions:

Fig 1.8 Shear crushing

As a mechanical reduction method, compression should be used as follows:

Dept. of Mechanical Engineering 8

—if the material is not sticky

Fig 1.9 Compression crushing

1.4 Scope of Project

Dept. of Mechanical Engineering 9

3. [RS Khurmi has published a book “Strength of Materials”, Publications

5. [S. Md. Jalaludeen has published a book “Design data handbook”]

Dept. of Mechanical Engineering 10

3.1 Construction of machine

Dept. of Mechanical Engineering 11

Dept. of Mechanical Engineering 12

3.2 Operating Principle

3.3 Working of machine

Dept. of Mechanical Engineering 13

Fig 3.1Hammer Mill crusher

Dept. of Mechanical Engineering 14

3.4 Hammer mill features:

3.5 Applications of Hammer mill crushers:

Dept. of Mechanical Engineering 15

The following stresses are induced in the shafts:

4.1 Classification of shafts

Shafts involved in power transmission may be classified as

Dept. of Mechanical Engineering 16

4.2 Material used for shafts

4.3 Design of shafts

Dept. of Mechanical Engineering 17

Shafts subjected to twisting moment or torque only:

Fs =Torsional shear stress, N/ m

We know for solid shaft, polar moment of inertia,

The equation may be written as

Dept. of Mechanical Engineering 18

Twisting moment (T) may be obtain by the following relation:

In S.I units, power transmitted (in watts) by the shaft,

In M.K.S units, horse power transmitted by the shaft,

Shafts subjected to bending moment only:

Dept. of Mechanical Engineering 19

Fb =Bending stress, N/ and

We know that for a round solid shaft, moment of inertia,

Substituting these values in the equation:

T = (6037.310^3) / (2* * 740)